Method for producing metallic material



' arch 7, 1939. H. w. GILLET T ET AL 2,149,596

METHOD FOR PRODUCING METALLIC MATERIAL ed June. 8, 1936 INVENTOR S HORACE W. GILLETT RUSSELL W. DAY TON M." m M 1 A TTORNEYS Patented Mar. 7, i939 METHOD FOR PRODUCING METALLIC MATERIAL Horace W. Gillet t and Russell W. Dayton, lumbus, Ohio, assignors to The Bunting Brass dz Bronze Company, Toledo,'0liio, a corporation of Ghio Application June's. 1936, Serial No. 84,233

9 Claims.

known; it also includes a new process for obtaining such material and a novel apparatus.

One of the objects of the invention is to successfully utilize scrap materials, such as bronze machinings, and thereby convert a waste product of little value into a product of economic importance.

Another object is to obtain metallic materials having such properties as to adapt the same for many useful purposes such, for example, as oilless bearings and other articles where a certain degree of porosity is desired.

A further. object is to obtain a process for integrating comminuted materials in such a way as tocontrol the porosity of the final material 25 and also to control the ratio of the closed pores to the open pores which have absorptive power. Another object of the invention is to-obtain a process for integrating materials to obtain desirable chemical and physical properties. 30' These and other objects may be obtained by utilizing the apparatus and the methods hereinafter more fully described and illustrated in the accompanying drawing, wherein Figure l is a diagrammatic view showing an elevation of one form of apparatus;

1 be used. The cylinder bore H has inserted therein at opposite ends thereof the cylindrical electrodes l2 and is which are composed of materials having good electrical conductivity and other electrodes. Between the two electrodes is placed the comminuted material it which is to be integrated by the process. Such material may, for the purpose of illustration, be considered to be bronze machinings. It hasbeen found prefere0 able to place between the metal particles id and Figure 2 is across sectional view thereof on properties characteristic of the standard welding;

the ends of the electrodes relatively thin washers l5 and lficonstructed of material whose electrical andthermal conductivity approaches the average conductivity of the mass of metal particles. As shown, these washers are separate members, but if desired they may be formed integral with the electrodes, or the ends of the electrodes themselves may be suitably modified to obtain the characteristics desired. The electrodes l2 and 93 are electrically connected to bus bars ill and i8 and the entire device is placed in a suitable press l9 which serves to regulate the pressure between the electrodes and to provide the necessary movement of the electrodes. As diagrammatically illustrated, the press has the upper fixed bearing plate 2!] and a lower movable bearing plate 29, the latter having a piston shank 22 .slidable within a hydraulic cylinder 23.

In the operation of the apparatus as thus far described, a predetermined amount of comminuted metal particles is placed between the washers at the ends of the electrodes and a predetermined pressure is applied to the electrodes by means of the hydraulic press. The electric circuit is then completed causing the current to pass from one electrode to the other through'the metal particles. A suitable timing device is provided for determining the length of time of the current flow, and one simple form of such timing device consists of a fuse 2d of such material and dimensions as to blow after a predetermined time interval. In the preferred embodiment of the invention, the apparatus is constructed to use a high current density, passing for a short interval of time as it has been found that these conditions improve the physical properties of the integrated material. The integration is accomplished by the combined influences of the passage of the electric current and the pressure on the electrodes.

One of the important features of this invention consists in so determining the pressure on the electrodes as to obtain the maximum ,benefit from the pinch efiect. The pinch effect caused by the passage of the electric current tends to draw the comminuted materials together dia metrically away from the side walls of the cylinder as indicated in Figure 3. By balancing the axial pressure on the electrodes with that due to the pinch effect, a true hydrostatic pressure is produced, resulting in a product free from planes of weakness. Thus the pressure must be properly determined to compensate for the tendencies of the particles to move inwardly away from the side walls and to maintain the particles in substantial contact with the side walls. As there is a shrinkage during the integration, it is f'ssential' d not only that the pressure should be maint at the desired value, but also that the, be capable of quickly following up the n efiect and to maintain the partIcI'esiiffiilPvOl greater ume within the cylinder and between the electrodes.

When the passage 'of the current through the mass is discontinued by the timing device, the comminuted particles have become an integrated mass and may be removed from the cylinder. The chemical and physical properties of the integrated material depend upon the relation of the variable factors, and a discussion of these factors is hereinafter given.

. In order to illustrate some of the important features of the invention, a number of examples of specific tests will be given. In these tests the apparatus used was the construction illustrated in Figures 1 and 2 in which the diameter of the cylinder H is one-half inch and the distance between the electrodes may be varied from onequarter inch to one-and-one-half inches. The current used was 1770 amperes. The comminuted material consistedof chamferings from a non-ferrous alloy containing 80% copper, tin and 10% lead. The chamferings were i-rregularly shaped particles having greater length than width and of a size such that all would pass a 30-mesh sieve and stay on a. 40-mesh sieve. according to our process into a mass one-half inch long, the following table illustrates the compressional strength of different products under certain varying conditions:

In the above table the metal chamferings were cleaned prior to being subjected to the process. Where the material was used without cleaning, it was found. that the compressional strength was reduced from 150,000 pounds per square inch, as indicated in Test No. 1, to 120,000 pounds per square inch.

It will be observed from the above tests that there is a relationship between the density of the final material and the compressional strength thereof. As the material becomes more dense. it also has a higher compressional strength. It is of interest also to note that with a constant pressure as in Testsl and 2, a lower time interval for the current passage results in a product of porosity and lesser compressional strength than a greater time of treatment. Also comparing Tests 1 and 3 where the time remains constant, a greater pressure on the electrodes increases the porosity and lowers compressional strength.

As will be noted in the table, with other conditions remaining constant and within the low pressure ranges contemplated herein, an increase of pressure results in an increase of porosity and a corresponding decrease in strength of the fln ished material. The density of the article does not depend upon the mold pressure per se, because thepressures are so low that they cannot deform thecold particles to any substantial extent. The extent of sintering is, however, very dependent upon the amount of electrical heat generated in the mass of particles. As is well understood, in a mass of compressed particles,

the electrical, resistance of the mass decreases verympidlyasthepressureisincreasedbecauctbemalorltyoftbereslstmceiscontact When these chamferings were integrated the metal particles.

resistance, between one particle and' another, for this decreases as the contact is improved by higher pressures. The line resistance being substantially constant higher pressure causes a lower resistance to an electrical current in the mold and therefore a smaller amount of heat generated within the mold. Furthermore, at the lower pressures, the heat generated by the passage of the electric current substantially limited to the points of contact between adjacent particles. The effect may be likened to relatively intense local heat at the points of contact with only incidental and substantially lower heating of the bodies of the particles. For these reasons higher pressures cause a less complete sintering and a greater porosity.

One of the important uses of our invention is to produce materials having a high degree of porosity. Such material may be used, for example, to construct salf-lubricating bearings in which the lubricating agent is absorbed in the be varied at will by varyingthe factors of time.

and pressure. I

As previously indicated, one of the important features of our invention is that our process utilizes the pinch effect to provide a stronger product free from planes of weakness. It is therefore important that the mechanism for applying axial pressure to the electrodes be capable of maintaining the desirable balance between axial pressure and the radial pressure due to the pinch eflfect. In general therefore, the pressure should be such that it is limited on the low side to such apressure as will prevent the particles from being moved away from the cylinder walls.

The mechanism must also have suilicient speed to cause the electrodes to follow up the shrinkage which occurs during the process and thereby maintain electrical contact. The pressure may be increased to greater values whenever this is necessary or desirable to obtain the desired characteristics in the final material.

It was previously pointed out that thewashers I5 and 16 should have certain thermal characteristics. .The thermal conductivity should be such that it approaches the average of the thermal conductivity of the mass between its initial and final conditions. Thus copper is not desirable because its thermal conductivity is too high, while graphite has too low a conductivity. The ferrous metals have been found to be satisfactory, either iron or mild steel, but in lieu thereof many other materials might be substituted such, for example, as aluminum-bronze, nickel and some other rarer metals and alloys, the use of which however is not required since the less expensive materials are satisfactory.

gas such as nitrogen, a reducing gas such as hydrogen, or a reducing atmosphere may be obtained by the decomposition of organic liquids such as alcohol or lower hydrocarbons mixed with During welding, such liquids will volatilize and force their way out of the material, insuring that the porosity is continuous, from one hole to the next.

Another modification of a process consists in do-slrlng orreplacingthealrlnthepressedarti ele ore to by as. or m- By the regulation of time and pressure during ii the welding operation, material of any desired degree of porosity can result from to 40%. l'he porous articles are particularly adapted for such oil filters and Our method-when used for such an article eliminotes melting losses, molding costs and dangers 1..

' said particles under a pressure within a limited of? defective mete ex. and, in addition, is ac rinl from scrap ms 119 other pm, invention consists in couted particles due to gas and segregation such a non-porous matc- ;=.1 having little value for of an alloy he as high a lead content as can he sotisioctorily oned by casting methods and i 'il' Eidditiilllfil lead w the in l litter the integrating p w-n' a final product is then'oh-- ed virs ptiomlly high lead cont. ther r: cation of our invention cots in utilizing powdered or comminuted metals of to erent composition in such proportions es to obtain a final product comprising on oy oi these .metoh in the ded proportions.- -ztoabove, it will be evident invention is suscepe oi various H; coil as and t it includes developt of new metollic tas well no a new 1- w and o in: from cnuted mate. t we cl as our invention ism l. The method oi pool omof an up such m bronze having conductivity, won comprises m v on, passing electric current 1:

w ot a c l ent density sufilcient-to cause to pinch efieet applying the s.

1a.: 4 an chenecuwo & p edete in i 1a-? =1 density cuprousalioy on said u s pinch eilect irom chins 1 said t v:. 5! I A material svhich 0081? confining a 0! m in a receptacle of e a current throush ty to saw a pinch eilect, apply a, c was m i-,. 1 the v the volume-o! sai c. the value which wlllbalsnce saidandtain clesin contactwith s cce ses j i a 3 Another modification of our that our new type oi cppsrntus for to inteted them ollcles;

' substantially cles, the current helm of sugcient or by 'alimitedranzeiustabovethe to balance said pinch ume, r a sintering current through said confined particles, thecurrent being of s'uilicient density to cause a pinch eflect, apply a pressure simultaneous with the passage. of current, by

varying the volume '01 said receptacl the value 8 -01 such pressure being the minimum pressure which will balance said pinch effect and maintain said particles in substantial contact with the sides of said receptacle, said particles being machinings of a copper containing alloy, and disl0 continuing said current and pressure as soon as sintering iscompiete;

, -5. Theprocessoi makinsan integrated porous material which comprlsesflplacing'comminuted metallic particles in an insulating mold, p is an electric current'therethrough of suflicient cur- 1 rentoensity to cause a pinch eiiect, maintaining range just above a pressure sumclent to balance after a predetermined interval.

6. The process 0! making an integrated porous material which comprises placing couted metallic particles in an insulating mold in contactwith spacedeleotrcdes having an electrical and thermal conductivity which approaches the average electrical and thermal conductivity of the mass oicles, von electric current 'therethrough -"o i sumcient -current density to cause a pinch efiectmain said particlestil under a pressure onlY'SIiBhfly eater than suflicient tohslance the pinch effect, and discontinupaid current eiter'a predetermined interval. 7 7 The process of mak an integrated porous material which comprises placing tact with smced electrodes having an electrical and thal conductivity which approaches the average-electrical and thermal conductivity of an electric current therethroueh cl sufilcient current density to causes pinch eflect, main said particles under a pr'only htly'greater than sum- ..cient to balance the m'seid close; and discontin said 4 current alter a in.

pinch, eilect by relatively 3. Theta! o I n comics po i w", 11 an m ted lee-in an-insula mold in con-" tact with}; ','electrodes having an electrical w ill I an electric current'thercthrough or sum'cient current density to cause a pinch eil ect, applying I.

pressure'to said particles'by application of lorce substantially transverse tothe direction of action a couted 38 metallic particles'in an insulating mold in con-. 

